EP3260562B1 - Improving hot workability of metal alloys via surface coating - Google Patents

Improving hot workability of metal alloys via surface coating Download PDF

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Publication number
EP3260562B1
EP3260562B1 EP17179737.6A EP17179737A EP3260562B1 EP 3260562 B1 EP3260562 B1 EP 3260562B1 EP 17179737 A EP17179737 A EP 17179737A EP 3260562 B1 EP3260562 B1 EP 3260562B1
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EP
European Patent Office
Prior art keywords
workpiece
alloy
glass
surface coating
alloy workpiece
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EP17179737.6A
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German (de)
English (en)
French (fr)
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EP3260562A1 (en
Inventor
Robin M Forbes Jones
Richard L Kennedy
Ramesh S Minisandram
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ATI Properties LLC
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ATI Properties LLC
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J3/00—Lubricating during forging or pressing
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C23/00—Extruding metal; Impact extrusion
    • B21C23/32—Lubrication of metal being extruded or of dies, or the like, e.g. physical state of lubricant, location where lubricant is applied
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J1/00—Preparing metal stock or similar ancillary operations prior, during or post forging, e.g. heating or cooling
    • B21J1/06—Heating or cooling methods or arrangements specially adapted for performing forging or pressing operations
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C21D7/06—Modifying the physical properties of iron or steel by deformation by cold working of the surface by shot-peening or the like
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/0278—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips involving a particular surface treatment
    • C21D8/0284—Application of a separating or insulating coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4981—Utilizing transitory attached element or associated separate material
    • Y10T29/49812—Temporary protective coating, impregnation, or cast layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49885—Assembling or joining with coating before or during assembling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49888—Subsequently coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49982—Coating
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/4998—Combined manufacture including applying or shaping of fluent material
    • Y10T29/49982—Coating
    • Y10T29/49986—Subsequent to metal working
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/131—Glass, ceramic, or sintered, fused, fired, or calcined metal oxide or metal carbide containing [e.g., porcelain, brick, cement, etc.]
    • Y10T428/1317—Multilayer [continuous layer]

Definitions

  • the present disclosure is directed to alloy ingots and other alloy workpieces, methods for processing the same and, in particular, methods for improving the hot workability of alloy ingots and other alloy workpieces by providing a surface coating thereon.
  • crack sensitive alloys may be characterized as being "crack sensitive". Ingots and other workpieces composed of crack sensitive alloys may form cracks along their surfaces and/or edges during hot working operations. Forming articles from crack sensitive alloys may be problematic because, for example, cracks formed during forging or other hot working operations may need to be ground off or otherwise removed, increasing production time and expense, and reducing yield.
  • dies apply a force to an alloy workpiece to deform the workpiece.
  • the interaction between the die's surfaces and the alloy workpiece's surfaces may involve heat transfer, friction, and wear.
  • One conventional technique for reducing surface and edge cracking during hot working is to enclose the alloy workpiece in a metal alloy can before hot working.
  • the inside diameter of the alloy can may be slightly larger than the outside diameter of the workpiece.
  • the alloy workpiece may be inserted into the alloy can such that the alloy can loosely surrounds the workpiece, and the dies contact the outer surfaces of the alloy can.
  • the alloy can thermally insulates and mechanically protects the enclosed workpiece, thereby eliminating or reducing the incidence of crack formation on the workpiece.
  • the alloy can thermally insulates the alloy workpiece by action of the air gaps between the workpiece and the alloy can's inner surfaces and also by directly inhibiting the alloy workpiece from radiating heat to the environment.
  • An alloy workpiece canning operation may result in various disadvantages.
  • mechanical contact between dies and the alloy can's outer surfaces may break apart the alloy can.
  • the alloy can may break apart during the draw operation.
  • the alloy workpiece may need to be re-canned between each upset-and-draw cycle of a multiple upset-and-draw forging operation, which increases process complexity and expense.
  • the alloy can may impair an operator from visually monitoring the surface of a canned alloy workpiece for cracks and other work-induced defects.
  • US 2,706,850 discloses a method of deforming metals, which comprises interposing between a metal workpiece and a deforming tool, a flexible sheet of intermingled fibers of glass-like material and deforming the workpiece at a temperature such as to cause the glass-like material to melt.
  • the invention provides a method for processing an alloy workpiece in accordance with claim 1 of the appended claims. According to certain non-limiting embodiments, methods for processing alloy ingots and other alloy workpieces are described.
  • a method of processing an alloy workpiece includes: depositing a glass material onto at least a portion of an alloy workpiece; and heating the glass material to form a surface coating on the alloy workpiece that reduces heat loss from the alloy workpiece.
  • the glass material is selected from a glass fabric, and a glass tape.
  • depositing the glass material onto at least a portion of the workpiece may include at least one of disposing, wrapping, and taping.
  • heating the glass material includes heating the glass material to a temperature from 537.8°C (1000°F) to 1204.4°C (2200°F).
  • the workpiece comprises a material selected from a nickel base alloy, a nickel base superalloy, an iron base alloy, a nickel-iron base alloy, a titanium base alloy, a titanium-nickel base alloy, and a cobalt base alloy.
  • the workpiece may comprise or be selected from an ingot, a billet, a bar, a plate, a tube, a sintered pre-form, and the like.
  • the method further includes, subsequent to heating the glass material, one or more steps selected from: applying a force with at least one of a die and a roll to the workpiece to deform the workpiece; hot working the workpiece, wherein hot working comprises at least one of forging and extruding; cooling the workpiece; removing at least a portion of the surface coating from the workpiece by at least one of shot blasting, grinding, peeling, and turning; and any combination thereof.
  • a method of hot working a workpiece includes: disposing a fiberglass blanket onto at least a portion of a surface of an alloy workpiece; heating the fiberglass blanket to form a surface coating on the workpiece; applying force with at least one of a die and a roll to the workpiece to deform the workpiece, wherein the at least one of the die and the roll contacts the surface coating on a surface of the workpiece; and removing at least a portion of the surface coating from the workpiece.
  • at least one of the die and the roll contacts at least one remnant of the surface coating on a surface of the workpiece.
  • the workpiece may comprise or be selected from an ingot, a billet, a bar, a plate, a tube, a sintered pre-form, and the like.
  • Yet further non-limiting embodiments according to the present disclosure are directed to articles of manufacture made from or including alloy workpieces made or processed according to any of the methods of the present disclosure.
  • article of manufacture include, for example, jet engine components, land based turbine components, valves, engine components, shafts, and fasteners.
  • the term “softening point” refers to the minimum temperature at which a particular glass material no longer behaves as a rigid solid and begins to sag under its own weight.
  • the term “about” refers to an acceptable degree of error for the quantity measured, given the nature or precision of the measurement.
  • a force may be applied to an alloy ingot or other alloy workpiece at a temperature greater than ambient temperature, such as above the recrystallization temperature of the workpiece, to plastically deform the workpiece.
  • the temperature of an alloy ingot or other alloy workpiece undergoing the working operation may be greater than the temperature of the dies or other structures used to mechanically apply force to the surfaces of the workpiece.
  • the workpiece may form temperature gradients due to cooling of its surface by heat loss to ambient air and the thermal gradient off-set between its surfaces and the contacting dies or other structures. The temperature gradients may contribute to surface cracking of the workpiece during hot working. Surface cracking is especially problematic in situations in which the alloy ingots or other alloy workpieces are formed from crack sensitive alloys.
  • the alloy workpiece may comprise a crack sensitive alloy.
  • various nickel base alloys, iron base alloys, nickel-iron base alloys, titanium base alloys, titanium-nickel base alloys, cobalt base alloys, and superalloys, such as nickel base superalloys may be crack sensitive, especially during hot working operations.
  • An alloy ingot or other alloy workpiece may be formed from such crack sensitive alloys and superalloys.
  • a crack sensitive alloy workpiece may be formed from alloys or superalloys selected from, but not limited to, Alloy 718 (UNS No. N07718), Alloy 720 (UNS No. N07720), Rene 41TM alloy (UNS No.
  • the alloy workpiece may comprise or be selected from an ingot, a billet, a bar, a plate, a tube, a sintered pre-form, and the like.
  • An alloy ingot or other alloy workpiece may be formed using, for example, conventional metallurgy techniques or powder metallurgy techniques.
  • an alloy ingot or other alloy workpiece may be formed by a combination of vacuum induction melting (VIM) and vacuum arc remelting (VAR), known as a VIM-VAR operation.
  • VIM-VAR operation vacuum induction melting
  • an alloy workpiece may be formed by a triple melting technique, in which an electroslag remelting (ESR) operation is performed intermediate a VIM operation and a VAR operation, providing a VIM-ESR-VAR (i.e., triple melt) sequence.
  • ESR electroslag remelting
  • an alloy workpiece may be formed using a powder metallurgy operation involving atomization of molten alloy and the collection and consolidation of the resulting metallurgical powders into an alloy workpiece.
  • an alloy ingot or other alloy workpiece may be formed using a spray forming operation.
  • VIM may be used to prepare a base alloy composition from a feedstock.
  • An ESR operation may optionally be used after VIM.
  • Molten alloy may be extracted from a VIM or ESR melt pool and atomized to form molten droplets.
  • the molten alloy may be extracted from a melt pool using a cold wall induction guide (CIG), for example.
  • the molten alloy droplets may be deposited using a spray forming operation to form a solidified alloy workpiece.
  • an alloy ingot or other alloy workpiece may be formed using hot isostatic pressing (HIP).
  • HIP generally refers to the isostatic application of a high pressure and high temperature gas, such as, for example, argon, to compact and consolidate powder material into a monolithic preform.
  • the powder may be separated from the high pressure and high temperature gas by a hermetically sealed container, which functions as a pressure barrier between the gas and the powder being compacted and consolidated.
  • the hermetically sealed container may plastically deform to compact the powder, and the elevated temperatures may effectively sinter the individual powder particles together to form a monolithic preform.
  • a uniform compaction pressure may be applied throughout the powder, and a homogeneous density distribution may be achieved in the preform.
  • a near-equiatomic nickel-titanium alloy powder may be loaded into a metallic container, such as, for example, a steel can, and outgassed to remove adsorbed moisture and entrapped gas.
  • the container containing the near-equiatomic nickel-titanium alloy powder may be hermetically sealed under vacuum, such as, for example, by welding.
  • the sealed container may then be HIP'ed at a temperature and under a pressure sufficient to achieve full densification of the nickel-titanium alloy powder in the container, thereby forming a fully-densified near-equiatomic nickel-titanium alloy preform.
  • a method of processing an alloy ingot or other alloy workpiece may generally comprise depositing an inorganic material onto at least a portion of an alloy workpiece and heating the inorganic material to form a surface coating on the workpiece that reduces heat loss from the workpiece.
  • the inorganic material may comprise one or more of a thermally insulating material comprising, for example, a material selected from a fabric, and a tape.
  • the inorganic material may comprise, for example, one or more of aluminum oxide, calcium oxide, magnesium oxide, silicon dioxide, zirconium oxide, sodium oxide, lithium oxide, potassium oxide, boron oxide, and the like.
  • the inorganic material may have a melting point or softening point of 260°C (500°F) or higher, such as, for example, 260°C (500°F) to 1371.1°C (2500°F) and 537.8°C (1000°F) to 1204.4°C (2200°F).
  • the method may comprise, for example, depositing the inorganic material onto at least a portion of the surface of the alloy workpiece and heating the inorganic material to form a surface coating on the workpiece and reduce heat loss from the workpiece.
  • heating the inorganic material includes heating the inorganic material to a forging temperature, such as 537.8°C (1000°F) to 1204.4°C (2200°F).
  • the composition and form of the inorganic material may be selected to form a viscous surface coating at the forging temperature.
  • the surface coating may adhere to the surface of the alloy workpiece.
  • the surface coating may be characterized as an adherent surface coating.
  • the surface coating according to the present disclosure also may lubricate surfaces of the alloy ingot or other alloy workpiece during hot working operations.
  • a non-limiting embodiment of a method of processing an alloy workpiece that reduces thermal cracking may generally comprise depositing an inorganic glass material onto a portion of an alloy ingot or other alloy workpiece and heating the glass material to form a surface coating on the workpiece and reduce heat loss from the workpiece.
  • the glass material comprises a thermally insulating material comprising one or more of a glassfabric, and a glass tape.
  • the glass material provided on the workpiece may form a viscous surface coating on the workpiece when the glass material is heated to a suitable temperature.
  • the composition and form of the glass material may be selected to form a viscous surface coating at a forging temperature.
  • the glass material surface coating may adhere to the surface of the workpiece and be retained on the surface up to and during hot working.
  • the glass material surface coating may be characterized as an adherent surface coating.
  • the glass material surface coating provided by heating the glass material may reduce heat loss from the alloy workpiece and eliminate or reduce the incidence of surface cracking resulting from forging, extrusion, or otherwise working the alloy workpiece relative to an otherwise identical alloy workpiece lacking such a surface coating.
  • the glass material surface coating according to the present disclosure also may lubricate surfaces of the alloy workpiece during hot working operations.
  • the inorganic fibers comprise glass fibers.
  • the glass fibers may comprise continuous fibers and/or discontinuous fibers. Discontinuous fibers may be made, for example, by cutting or chopping continuous fibers.
  • the glass fibers may comprise, for example, one or more of SiO 2 , Al 2 O 3 , and MgO.
  • the glass fibers may comprise, for example, magnesium alumino-silicate fibers.
  • the glass fibers may comprise, for example, magnesium aluminosilicate fibers selected from the group consisting of E-glass fibers, S-glass-fibers, S2-glass fibers, and R-glass fibers.
  • E-glass fibers may comprise one or more of SiO 2 , Al 2 O 3 , B 2 O 3 , CaO, MgO, and other oxides.
  • S-glass fibers and S2-glass fibers may comprise one or more of SiO 2 , Al 2 O 3 , MgO.
  • R-glass fibers may comprise one or more of SiO 2 , Al 2 O 3 , CaO, and MgO.
  • the inorganic fibers may comprise refractory ceramic fibers.
  • the refractory ceramic fibers may be amorphous and comprise one or more of SiO 2 , Al 2 O 3 , and ZrO 2 .
  • a plurality of the glass fibers may form a fabric.
  • fabric refers to materials that may be woven, knitted, felted, fused, or non-woven materials, or that otherwise are constructed of fibers.
  • the fabric may comprise a binder to hold the plurality of fibers together.
  • the fabric may comprise a yarn, a blanket, a mat, a paper, a felt, and the like.
  • the glass fibers may comprise a glass blanket.
  • the glass blanket may comprise, for example, E-glass fibers.
  • Exemplary glass blankets comprising E-glass fibers useful in embodiments according to the present disclosure include, but are not limited to, fibers commercially available from Anchor Industrial Sales, Inc. (Kernersville, N.C.) under the trade designation "Style 412" and “Style 412B” having a thickness of 0.157 cm (0.062 inches), E-glass fibers having a weight of 813.7 g/m 2 (24 oz./yd 2 ), and a temperature rating of 537.8°C (1000°F).
  • the glass fabric may comprise, for example, a fiberglass blanket, such as, for example, an E-glass blanket.
  • the fabric may have any suitable width and length to cover at least a portion of the workpiece.
  • the width and length of the fabric may vary according to the size and/or shape of the workpiece.
  • the thicknesses of the fabric may vary according to the thermal conductivity of the fabric.
  • the fabric may have a thickness from 1-25 mm, such as 5-20 mm or 8-16 mm.
  • the inorganic tape may comprise a glass tape.
  • the glass tape may comprise a glass backing and an adhesive.
  • the glass backing may comprise, for example, one or more of aluminum oxide, calcium oxide, magnesium oxide, silicon dioxide, zirconium oxide, sodium and sodium oxide, lithium oxide, potassium oxide, boron oxide, and the like.
  • the glass backing may comprise a glass fiber, such as a glass yarn, a glass fabric, and a glass cloth.
  • the glass backing may comprise a glass filament.
  • the glass tape may comprise a fiberglass filament reinforced packing tape.
  • the glass tape may comprise an adhesive tape including a glass cloth backing or a tape impregnated with glass yarn or filament.
  • the glass tape may comprise a polypropylene backing reinforced with continuous glass yarn.
  • the glass tape may have characteristics including: an adhesion to steel of about 55 oz./in. width (60 N/100 mm width) according to ASTM Test Method D-3330; a tensile strength of about 300 Ibs./in. width (5250 N/100 mm width) according to ASTM Test Method D-3759; an elongation at break of about 4.5% according to ASTM Test Method D-3759; and/or a total thickness of about 6.0 mil (0.15 mm) according to ASTM Test Method D-3652.
  • Exemplary glass tapes useful in embodiments according to the present disclosure are commercially available from 3M Company (St. Paul, Minn.) under the trade designation SCOTCH® Filament Tape 893.
  • a method of processing an alloy ingot or other alloy workpiece in a way that reduces thermal cracking during hot working may generally comprise disposing a glass fabric onto at least a portion of a surface of the workpiece.
  • the fabric may be disposed onto a substantial portion of the surface of the workpiece.
  • the surface of a alloy workpiece may comprise, for example, a circumferential surface and two lateral surfaces disposed at each end of the circumferential surface.
  • the fabric may be disposed onto a substantial portion of a circumferential surface of a cylindrical alloy workpiece.
  • the fabric may be disposed onto the circumferential surface of the cylindrical workpiece and at least one lateral surface of the cylindrical workpiece.
  • a glass blanket may be disposed onto at least a portion of a circumferential surface of a cylindrical alloy workpiece and at least one lateral surface of the cylindrical workpiece.
  • more than one glass fabric such as two, three, or more, may each be disposed onto at least a portion of a surface of a cylindrical workpiece and/or at least one lateral surface of the cylindrical workpiece.
  • the fabric may be disposed by transversely wrapping the fabric around the circumferential surface of the workpiece, for example.
  • the glass fabric may be secured to the workpiece using adhesives and/or mechanical fasteners such as, for example, glass tape and bale wire.
  • a method of processing an alloy ingot or other alloy workpiece so as to reduce thermal cracking during hot working may comprise repeating the step of disposing a glass fabric onto at least a portion of the surface of the workpiece.
  • the fabric may be wrapped around the workpiece at least one time, two times, three times, four times, or more than four times.
  • the fabric may be wrapped around the workpiece until a predetermined thickness is achieved.
  • more than one glass fabric may be disposed onto at least a portion of a circumferential surface of a cylindrical workpiece and at least one of each lateral surface of the cylindrical workpiece until a predetermined thickness is achieved.
  • the predetermined thickness may be from 1 mm to 50 mm, such as 10 mm to 40 mm.
  • the method may comprise disposing a first glass fabric onto at least a portion of the surface of the workpiece and a second glass fabric onto at least one of the first glass fabric and at least a portion of the surface of the workpiece.
  • the first glass fabric and the second glass fabric may comprise the same or different inorganic materials.
  • the first glass fabric may comprise a first E-glass blanket and the second glass fabric may comprise a second E-glass fabric.
  • the first glass fabric may comprise an E-glass blanket and the second glass fabric may comprise a ceramic blanket, such as, for example, a KAOWOOL blanket, which is a material produced from alumina-silica fire clay.
  • a method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may generally comprise disposing a glass tape onto at least a portion of the surface of the workpiece.
  • the tape may be disposed onto a substantial portion of the surface of the workpiece.
  • the tape may be disposed onto a circumferential surface of a cylindrical workpiece and/or at least one lateral surface of the workpiece.
  • Disposing the tape onto a surface of the workpiece may comprise, for example, one or more of wrapping and taping.
  • the tape may be disposed by transversely wrapping the tape around the circumferential surface of the workpiece.
  • the tape may be disposed onto a surface by adhering the tape onto the surface of the workpiece. In certain non-limiting embodiments, the tape may be disposed onto at least a portion of a surface of a cylindrical alloy workpiece and/or at least a portion of a glass blanket.
  • FIG. 13 is a photograph of an alloy workpiece in the form of an alloy ingot, and which includes a glass tape disposed on the circumferential surface of the workpiece and on the opposed ends or faces of the workpiece.
  • a method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may comprise repeating one or more times the step of disposing a glass tape onto at least a portion of the surface of the workpiece.
  • the tape may be wrapped around the workpiece at least one time, two times, three times, four times, or more than four times.
  • the method may comprise wrapping a first glass tape onto at least a portion of a surface of the workpiece and wrapping a second glass tape onto at least one of the first glass tape and at least a portion of an un-taped surface of the workpiece.
  • the method may comprise taping a first glass tape to at least a portion of the surface of the workpiece and a second glass tape to at least one of the first glass tape and at least a portion of the un-taped surface of the workpiece.
  • the first glass tape and the second glass tape may comprise the same or different inorganic materials.
  • the tape may be disposed on the alloy workpiece until a predetermined thickness is achieved.
  • more than one glass tape may be disposed onto at least a portion of a circumferential surface of a cylindrical alloy ingot or other alloy workpiece and at least one of each lateral surface of the cylindrical workpiece until a predetermined thickness is achieved.
  • the predetermined thickness may be, for example, from less than 1 mm to 50 mm, such as 10 mm to 40 mm.
  • the glass material provided on the alloy workpiece may form a viscous surface coating on the workpiece when the glass material is heated.
  • the workpiece comprising the glass material thereon may be heated in a furnace.
  • the composition of the glass material may be selected to form a viscous surface coating at the forging temperature.
  • the oxides comprising the glass material may be selected to provide a glass material having a melting point or softening point at a predetermined temperature, such as a forging temperature.
  • the form of the glass material i.e ., a fabric, a tape, and any combinations thereof, may be selected to form a viscous surface coating at a predetermined temperature, such as, a forging temperature.
  • a glass fabric provided on a surface of the workpiece may form a viscous surface coating on the workpiece when the glass material is heated, for example, in a furnace at a temperature from 1037.8°C-1148.9°C (1900°F to 2100°F).
  • a glass tape provided on a surface of the workpiece may form a viscous surface coating on the workpiece when the glass material is heated, for example, in a furnace at a temperature from 1037.8°C-1148.9°C (1900°F to 2100°F).
  • a surface coating provided on a surface of an alloy ingot or other alloy workpiece may be characterized as an adherent surface coating.
  • the viscous surface coating may form an adherent surface coating when the surface coating is cooled.
  • the viscous surface coating may form an adherent surface coating when the workpiece comprising the surface coating is removed from the furnace.
  • a surface coating may be characterized as being "adherent" when the surface coating does not immediately flow off of a workpiece surface.
  • a surface coating may be considered “adherent" when the coating does not immediately flow off the surface when the alloy ingot or other alloy workpiece is removed from the furnace.
  • a surface coating on a circumferential surface of an alloy workpiece having a longitudinal axis and a circumferential surface may be considered “adherent" when the coating does not immediately flow off the circumferential surface when the workpiece is disposed so that the longitudinal axis is vertically oriented, such as, for example, at 45° to 135° relative to a horizontal surface.
  • a surface coating may be characterized as a "non-adherent" surface coating when the surface coating immediately flows off of the surface of the workpiece when the workpiece is removed from the furnace.
  • the temperature range over which alloys may be hot worked may take into account the temperature at which cracks initiate in the alloy and the composition and form of the inorganic material. At a given starting temperature for a hot working operation, some alloys may be effectively hot worked over a larger temperature range than other alloys because of differences in the temperature at which cracks initiate in the alloy. For alloys having a relatively small hot working temperature range (i.e., the difference between the lowest temperature at which the alloy may be hot worked and the temperature at which cracks initiate), the thickness of the inorganic material may be relatively greater to inhibit or prevent the underlying workpiece from cooling to a brittle temperature range in which cracks initiate. Likewise, for alloys having a relatively large hot working temperature range, the thickness of the inorganic material may be relatively smaller to inhibit or prevent the underlying alloy ingot or other alloy workpiece from cooling to a brittle temperature range in which cracks initiate.
  • a method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may generally comprise heating the inorganic material to form a surface coating on the workpiece.
  • Heating the inorganic material may comprise, for example, heating the inorganic material to a temperature from 260°C-1371.1°C (500-2500°F), such as, for example, 260°C-815.6°C (500-1500°F), 537.8°C-1093.3°C (1000-2000°F), 815.6°C-1093.3°C (1500°F-2000°F), or 1093.3°C-1371.1°C (2000-2500°F), to form the surface coating.
  • the inorganic fibers such as glass blankets and glass tapes, may be heated to a temperature from 1093.3°C-1371.1°C (2000-2500°F).
  • the temperature may be greater than the melting point of the inorganic material.
  • the temperature may be greater than the temperature rating of the inorganic material.
  • the temperature may be greater than the melting point of the glass fabric, glass particle, and/or glass tape.
  • the temperature may be greater than the melting point of the glass blanket.
  • inorganic materials may not have a specific melting point and may be characterized by a "softening point".
  • ASTM Test Method C338-93 (2008) provides a standard test method for determining the softening point of a glass.
  • the inorganic material may be heated to a temperature that is at least the softening point of the inorganic material.
  • the surface coating may be formed on at least a portion of the surface of the alloy workpiece. In certain non-limiting embodiments, the surface coating may be formed on a substantial portion of the surface of the workpiece. In certain non-limiting embodiments, the surface coating may completely cover the surface of the workpiece. In certain non-limiting embodiments, the surface coating may be formed on a circumferential surface of the alloy workpiece. In certain non-limiting embodiments, the surface coating may be formed on a circumferential surface of the workpiece and at least one lateral face of the workpiece. In certain non-limiting embodiments, the surface coating may be formed on a circumferential surface of the workpiece and each lateral face of the workpiece.
  • the surface coating may be formed on at least a portion of the surface of the workpiece free from the inorganic material.
  • the inorganic material may be deposited onto a portion of the surface of the workpiece. The inorganic material may melt when heated. The melted inorganic material may flow to a portion of the surface of the workpiece on which the inorganic material was not deposited.
  • the inorganic material may be deposited to a thickness sufficient to form a surface coating thereon when heated, wherein the surface coating insulates the underlying workpiece surface from the surface of a contacting die, thereby inhibiting or preventing the underlying workpiece surface from cooling to a temperature at which the underlying workpiece surface may more readily crack during hot working.
  • greater hot working temperatures may generally correlate with a preference for greater surface coating thicknesses.
  • the surface coating may have a thickness suitable to reduce heat loss from the workpiece.
  • the surface coating may have a thickness of 0.1 mm to 2 mm, such as, for example, 0.5 mm to 1.5 mm, and about 1 mm.
  • the surface coating may reduce heat loss of the alloy workpiece and/or increase slippage of the workpiece relative to the die or other contacting surfaces during hot working.
  • the surface coating may act as a thermal barrier to heat loss from the workpiece through convection, conduction, and/or radiation.
  • the surface coating may reduce surface friction of the alloy workpiece and act as a lubricant, and thereby increase the slippage of the workpiece during a hot working operation, e.g., forging and extruding.
  • the inorganic material may be deposited to a thickness sufficient to lubricate the workpiece during hot working operations.
  • a method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may generally comprise cooling the workpiece including the surface coating. Cooling the workpiece may comprise cooling the surface coating. In certain non-limiting embodiments, cooling the workpiece may comprise air cooling the workpiece. In certain non-limiting embodiments, cooling the workpiece may comprise disposing a ceramic blanket, such as, for example, a KAOWOOL blanket, onto at least one of the surface coating and at least a portion of a surface of the workpiece. In certain non-limiting embodiments, the surface of the workpiece may be cooled to room temperature.
  • a ceramic blanket such as, for example, a KAOWOOL blanket
  • a method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may generally comprise removing at least one of at least a portion of the surface coating and/or remnants of the surface coating from the workpiece.
  • the method may comprise, after hot working, removing at least one of a portion of the surface coating and/or remnants of the surface coating from the product formed by hot working the workpiece.
  • Removing the surface coating or remnants may comprise, for example, one or more of shot blasting, grinding, peeling, and turning.
  • peeling the hot worked workpiece may comprise lathe-turning.
  • a non-limiting method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may generally comprise heating the workpiece and/or conditioning the surface of the workpiece.
  • an alloy workpiece may be exposed to high temperatures to homogenize the alloy composition and microstructure of the workpiece. The high temperatures may be above the recrystallization temperature of the alloy but below the melting point temperature of the alloy.
  • the workpiece may be heated to a forging temperature, the inorganic material may be deposited thereon, and the workpiece may be reheated to form a surface coating thereon.
  • the workpiece may be heated before depositing the inorganic material to reduce the furnace time necessary to bring the workpiece to temperature.
  • An alloy workpiece may be surface conditioned, for example, by grinding and/or peeling the surface of the workpiece.
  • a workpiece may also be sanded and/or buffed. Surface conditioning operations may be performed before and/or after any optional heat treatment steps, such as, for example, homogenization at high temperatures.
  • a method of processing an alloy ingot or other alloy workpiece to reduce thermal cracking may generally comprise hot working the workpiece.
  • Hot working the workpiece may comprise applying a force to the workpiece to deform the workpiece. The force may be applied with, for example, dies and/or rolls.
  • hot working the workpiece may comprise hot working the workpiece at a temperature from 815.6°C-1371.1°C (1500°F to 2500°F).
  • hot working the workpiece may comprise a forging operation and/or an extrusion operation.
  • a workpiece having a surface coating deposited onto at least a region of a surface of the workpiece may be upset forged and/or draw forged.
  • the method may comprise after forming a surface coating on the workpiece, hot working the workpiece by forging. In various non-limiting embodiments, the method may comprise after forming a surface coating on the workpiece, hot working the workpiece by forging at a temperature from 815.6°C-1371.1°C (1500°F to 2500°F). In various non-limiting embodiments, the method may comprise after forming a surface coating on the workpiece, hot working the workpiece by extruding. In various non-limiting embodiments, the method may comprise after forming a surface coating on the workpiece, hot working the workpiece by extruding at a temperature from 815.6°C-1371.1°C (1500°F to 2500°F).
  • An upset-and-draw forging operation may comprise one or more sequences of an upset forging operation and one or more sequences of a draw forging operation.
  • the end surfaces of a workpiece may be in contact with forging dies that apply force to the workpiece that compresses the length of the workpiece and increases the cross-section of the workpiece.
  • the side surfaces e.g., the circumferential surface of a cylindrical workpiece
  • forging dies that apply force to the workpiece that compresses the cross-section of the workpiece and increases the length of the workpiece.
  • an alloy ingot or other alloy workpiece having a surface coating deposited onto at least a region of a surface of the workpiece may be subjected to one or more upset-and-draw forging operations.
  • a workpiece may be first upset forged and then draw forged. The upset and draw sequence may be repeated twice more for a total of three sequential upset and draw forging operations.
  • a workpiece having a surface coating deposited onto at least a region of a surface of the workpiece may be subjected to one or more extrusion operations.
  • a cylindrical workpiece may be forced through a circular die, thereby decreasing the diameter and increasing the length of the workpiece.
  • Other hot working techniques will be apparent to those having ordinary skill, and the methods according to the present disclosure may be adapted for use with one or more of such other techniques without the need for undue experimentation.
  • the methods disclosed herein may be used to produce a wrought billet from an alloy ingot on the form of a cast, consolidated, or spray formed ingot.
  • the forge conversion or extrusion conversion of an ingot to a billet or other worked article may produce a finer grain structure in the article as compared to the former workpiece.
  • the methods and processes described herein may improve the yield of forged or extruded products (such as, for example, billets) from workpieces because the surface coating may reduce the incidence of surface cracking of the workpiece during the forging and/or extrusion operations.
  • a surface coating according to the present disclosure provided on at least a region of a surface of a workpiece may more readily tolerate the strain induced by working dies. It also has been observed that a surface coating according to the present disclosure provided onto at least a portion of a surface of an alloy workpiece may also more readily tolerate the temperature differential between the working dies and the workpiece during hot working. In this manner, it has been observed that a surface coating according to the present disclosure may exhibit zero or minor surface cracking while surface crack initiation is prevented or reduced in the underlying workpiece during working.
  • ingot or other workpieces of various alloys having a surface coating according to the present disclosure may be hot worked to form products that may be used to fabricate various articles.
  • the processes described herein may be used to form billets from a nickel base alloy, an iron base alloy, a nickel-iron base alloy, a titanium base alloy, a titanium-nickel base alloy, a cobalt base alloy, a nickel base superalloy, and other superalloys.
  • Billets or other products formed from hot worked ingots or other alloy workpieces may be used to fabricate articles including, but not limited to, turbine components, such as, for example, disks and rings for turbine engines and various land-based turbines.
  • Other articles fabricated from alloy ingots or other alloy workpieces processed according to various non-limiting embodiments described herein may include, but are not limited to, valves, engine components, shafts, and fasteners.
  • alloy workpieces that may be processed according to the various embodiments herein may be in any suitable form.
  • the alloy workpieces may comprise or be in the form of ingots, billets, bars, plates, tubes, sintered pre-forms, and the like.
  • the alloy workpiece may comprise a cylindrical alloy ingot.
  • Two generally cylindrical workpieces in form of ingots having a length of 26.4 cm (10 3/8 inches) and a width of 15.2 cm (6 inches), as generally shown in FIG. 2 were heat treated at 1148.9°C (2100°F) for 3 hours.
  • Each workpiece was wrapped in a KAOWOOL ceramic blanket and allowed to cool.
  • the KAOWOOL ceramic blanket was removed.
  • One workpiece was wrapped in a double layer of an E-glass blanket, as shown in FIG. 3 .
  • the E-glass blanket was secured to the workpiece using bale wire.
  • FIG. 4 is a photograph of the workpiece comprising the surface coating during forging.
  • FIG. 5 plots workpiece surface temperature over time during forging of the coated and uncoated workpieces.
  • the surface temperature of the coated workpiece (“Wrapped") during forging was generally about 50°C higher than for the uncoated workpiece ("Unwrapped”).
  • the surface temperature was measured using an infrared pyrometer.
  • FIGS. 6 and 7 are photographs of the forged coated workpiece (on the left in both photographs) and the forged uncoated workpiece (on the right in both photographs).
  • solidified remnants of the surface coating are visible on the surface of the coated workpiece.
  • FIG. 7 shows the coated workpiece after the remnants of the coating have been removed by shot blasting. Consideration of FIGS.
  • FIG. 8 is a chart plotting temperature over time during cooling of three 15.2 cm (6 inch) diameter Alloy 718 ingot workpieces during a forging operation. Each workpiece was allowed to cool in ambient air. Each workpiece's temperature was measured using embedded thermocouples. The temperature was assessed at the following positions on each workpiece: on the surface of the center of the workpiece; 1.3 cm (0.5 inches) below the surface on a left region of the workpiece; and 1.3 cm (0.5 inches) below the surface on a right region of the workpiece. A first one of the three workpieces was wrapped in an E-glass blanket secured to the workpiece using bale wire.
  • An inorganic slurry comprising ATP-790 material (available from Advanced Technical Products, Cincinnati, OH) was brushed onto the outer surface of the E-glass blanket. A portion of the surface of a second workpiece was wrapped in an E-glass blanket and a 1 inch thick KAOWOOL ceramic blanket. The third workpiece was left uncovered. The workpieces were heated to a forging temperature, and E-glass blanket/inorganic slurry and E-glass blanket/KAOWOOL blanket on the first and second workpiece, respectively, formed a surface coating on the workpieces that adhered to the workpieces' surfaces.
  • ATP-790 material available from Advanced Technical Products, Cincinnati, OH
  • FIG. 8 the presence of the surface coatings significantly decreased the cooling rates of the coated workpieces. It is believed that decreasing the cooling rate may reduce the incidence of surface cracking in the workpiece during forging, extrusion, or other hot working operations.
  • the workpiece without a surface coating cooled significantly faster than the workpieces comprising a surface coating.
  • the uncoated workpiece cooled from the forging temperature (approx. 1065.6°C (1950°F)) down to 148.9°C to 315.6°C (300°F to 600°F) (depending on the temperature measurement location) over a period of less than 3 hours.
  • FIG. 9 is a photograph of the workpiece comprising the E-glass blanket/KAOWOOL surface coating.
  • the workpiece comprising the E-glass blanket/ATP-790 inorganic slurry surface coating cooled faster than the workpiece comprising the E-glass blanket/ceramic blanket surface coating.
  • the workpiece comprising the E-glass blanket/ATP-790 inorganic slurry surface cooled from the forging temperature down to 204.4°C to 315.6°C (400°F to 600°F) (depending on the temperature measurement location) over a period of about 5 to 6 hours.
  • An alloy workpiece in the form of a generally cylindrical uncoated ingot of 718Plus® alloy (UNS No. N07818) was hot forged from a diameter of 50.8 cm (20 inches) down to a diameter of 35.6 cm (14 inches).
  • the workpiece developed extensive surface cracks during the forging operation.
  • the forged workpiece was turned down to 30.5 cm (12 inches) diameter to remove the surface cracks.
  • the turned workpiece was then hot forged from 30.5 cm (12 inches) to 25.4 cm (10 inches), and one end of the workpiece cracked extensively during forging.
  • the workpiece was then surface conditioned by shot blasting and a first end of the workpiece was hot forged from 25.4 cm (10 inches) to 15.2 cm (6 inches).
  • An E-glass blanket was wrapped around and secured to the second end of the forged workpiece, and the workpiece was placed in a furnace at a temperature of 1065.6°C
  • FIG. 10 is a photograph of the partially forged and partially coated workpiece after the workpiece was removed from the furnace. The end comprising the surface coating was forged from 30.5 cm (12 inches) down to 15.2 cm (6 inches), allowed to cool, and then shot blasted to remove the surface coating. The surface coating adhered to the surface of the second end of the workpiece during the forging operation, reducing heat loss from the second end.
  • FIG. 11 is a photograph showing the forged uncoated end of the workpiece (left photograph) and the forged coated end of the workpiece (right photograph) after shot blasting. The black spots on the surface of the forged coated workpiece after shot blasting are remnants of the surface coating.
  • An alloy workpiece in the form of a 3.8 cm (1.5 inch) diameter generally cylindrical titanium Ti-6AI-4V alloy (UNS No. R56400) ingot was heated in a furnace at a temperature of 815.6°C (1500°F) for 1.5 hours.
  • the heated workpiece was rolled in glass particles comprising Oxylub-327 material (available from Advance Technical Products, Cincinnati, Ohio), which has a metal hot-working range of 760°C-1010°C (1400-1850°F).
  • the workpiece was then placed in the furnace for an additional 30 minutes, and the glass particles formed a surface coating on the workpiece during the heating operation.
  • the coated workpiece was then forged three times in three independent directions.
  • FIG. 12 is a photograph of the workpiece after forging, and the adherent surface coating is evident in the photograph. The surface coating adhered to the surface of the workpiece during the forging operation and reduced heat loss from the workpiece.
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